ECHOTEL® MODELS 915-P / 915-W Installation and Operating Manual Ultrasonic Contact Level Switch 7xxx 6xxx 5xxx 4xxx 3xxx 2xxx 1xxx ® UNPACKING Unpack the instrument carefully. Make sure all components have been removed from the foam protection. Inspect all components for damage. Report any concealed damage to the carrier within 24 hours. Check the contents of the carton/crates against the packing slip and report any discrepancies to Magnetrol. Check the nameplate model number (Model number/approvals as per inserted separate sheet) to be sure it agrees with the packing slip and purchase order. Check and record the serial number for future reference when ordering parts. Nameplate: - part number - serial n° tag n° These units are in compliance with: 1. The EMC directive 89/336/EEC. The units have been tested to EN 61000-6-4 & EN 61000-6-2. 2. Directive 94/9/EC (ATEX 95A) for equipment or protective system intended for use in potentially explosive atmospheres. EC-type examination certificate number ISSeP00ATEX008X (915-P only) - intrinsically safe and ISSeP03ATEX100 (915-P only) explosion proof. MOUNTING Ambient temperature: -40°C (-40°F) to + 70°C (160°F) Hi alarm Filling line Lo alarm Hi alarm Max pressure: metal transducer: 103 bar (1500 PSIG) Kynar® transducer: 19 bar (275 PSIG) Max temp: metal transducer: 150°C (300°F) Kynar® transducer: 120 °C (250 °F) Min temp: -40°C (-40°F) Pump protection Lo alarm Pump ;;; @@@ ;;;; @@@@ ;;; @@@ ;;;; @@@@ ;;; @@@ ;;;; @@@@ Threaded 1" BSP connection 2 ;;;; @@@@ ;;;; @@@@ ; @ ; @ ;; @@ ;;;; @@@@ ; @ ; @ ;; @@ Welded flange ANSI/DIN connection Sanitary DIN 11851 connection Sanitary 3A connection WIRING Echotel® 915-P electronics Echotel® 915-W electronics ® Echotel 915W ® Echotel 915P + – Hi-Level Failsafe Max. Sicherheit Überfüllsicherung Pumpenschutz Min. Sicherheit Lo-Level Failsafe J3 Alarm Normal J2 Sensor plug for selftest J1 P/N: 030-9014-001 + Hi-Level Failsafe Max. Sicherheit Überfüllsicherung – Hi/Lo level dip switch Pumpenschutz Min. Sicherheit Lo-Level Failsafe J2 Alarm Normal Red LED = alarm Green LED = no alarm Sensor plug. P1 fits to J1 / P2 fits to J2. J1 Note: check the malfunction (5 mA) by unplugging either J1 or J2. Replace the phono after the test. P/N: 030-9006-001 Order number for replacement of electronic module Shield to green grounding screw External grounding screw Cable gland Shield not connected Standard shielded twisted pair cable (recommended but not needed when wired as per NAMUR NE 21 for field strenghts up to 10 V/m). HAZARDOUS AREA SAFE AREA Standard trip amplifier card Important: Connect the unit to the ground for avoiding earth potential drifts. Use either the external or internal grounding screw or both. FAILSAFE – ALARM STATUS Mode Level Output signal LED indication green (safe mode) red (alarm mode) 16 mA ± 1 mA = lit (on) High level failsafe 8 mA ± 1 mA = unlit (off) 16 mA ± 1 mA Low level failsafe 8 mA ± 1 mA 3 SPECIFICATIONS PHYSICAL/FUNCTIONAL SPECIFICATIONS Description Specification Input Voltage 10-35 V DC (24 V DC) – 2 wire loop powered Power Consumption 1 Watt maximum Normal operation 16 mA ± 1 mA Signal Output Alarm 8 mA ± 1 mA Malfunction 5 mA ± 1 mA Normal operation Green LED on Indication Alarm Red LED on Malfunction No LED’s on Housing material Approvals IP65, cast aluminium or stainless steel ATEX (metal transducers) II 1 G EEx ia II C T6, intrinsically safe - ambient temp. up to +55 °C (+130 °F) II 1 G EEx ia II C T5, intrinsically safe - ambient temp. up to +70 °C (+160 °F) II 1/2 G EEx d II C T6, explosion proof FM/CSA Non incendive, intrinsically safe and explosion proof Overfill Prevention TÜV - WHG § 19 / VLAREM II 5.17.7 SIL (Safety Integrity Level) Functional safety to SIL 2 loops / SIL 3 loops (redundant installation) – full FMEDA report by Exida available Electrical data Ui = 28,4 V, li = 94 mA, Pi = 0,67 W Equivalent data Ci = 25 nF, Li = 400 µH Shock/Vibration ANSI/ISA-dS71.03 SA1 (shock), ANSI/ISA-dS71.03 VC2 (vibration) Net Weight 1,6 kg / 3.5 lbs (unit with 50 mm SST transducer) TRANSDUCERS SPECIFICATIONS Description 9W1 transducers (plastic) 9D1 transducers (metal) 316/316L SST (1.4401/1.4404) Kynar® (PVDF) Hastelloy® C (2.4819) Monel® (2.4360) Threaded (NPT) – Flanged (ANSI - EN/DIN) From 40 mm up to 3300 mm (2" up to 130") From 30 mm up to 3300 mm (1" up to 130") -40 °C up to 120 °C (-40 °F up to 250 °F) -40 °C up to 150 °C (-40 °F up to 300 °F) 19 bar @ 40 °C (275 psi @ 100 °F) 103 bar @ 150 °C (1500 psi up to 300 °F) Flanged models are downrated to the design pressure of the selected flange 10.000 cP Transducer materials Mounting Actuation length Max process temp. Max pressure Max viscosity PRESSURE/TEMPERATURE RATING FOR 9W1 TRANSDUCERS (PLASTIC) PRESSURE/TEMPERATURE RATING FOR 9D1 TRANSDUCERS (METAL) bar (psi) bar ANSI RF Flange 15 (217) DIN Flange 10 (145) 3/4" NPT Threaded 5 (72) -40 (-40) 0 (32) 40 (100) 80 (176) 120 (250) Process temperature 4 (psi) 150 (2175) °C (°F) Process pressure Process pressure 20 (290) 103 bar 100 (1450) 50 (725) 25 (360) -40 (-40) 0 (32) 40 (100) 80 (176) 120 (250) Process temperature 150 °C (300) (°F) REPLACEMENT PARTS ① ② ③ No. Description 1 PC board 2 Cover EEx i Cover EEx d O-Ring Transducer 3 4 ④ Part Number 915-P22A-0X0 915-P32A-0X0 915-W22A-0X0 030-9006-001 030-9006-002 030-9014-001 04-9105-001 04-9105-005 12-2101-345 Consult part number description (see page 6) TROUBLESHOOTING Symptom Solution No signal with level change. Check wiring. A minimum of 10 V DC must be at the terminal block. Make sure liquid is filling the transducer gap. Check for dense foam on surface or dried product in the gap. Unit will not function properly if either condition exists. No change in loop current between wet gap or dry gap. Check to see if transducer gap is plugged with solids. Check for dense foam in gap. Output current at 0 mA. Check wiring to make sure input voltage is between 10 - 35 V DC. MODEL IDENTIFICATION A complete measuring system consists of: 1. One order code for electronics 2. One order code for transducer 1. Code for Echotel 915 – electronics 2-wire, 24 V DC potted electronics with 8 or 16 mA output 5 mA error signal SENSOR MATERIAL 9 1 5 – W 2 2 A 9 1 5 – P 2 2 A 9 1 5 – P 3 2 A Echotel 915W electronics for Kynar® (PVDF) transducer Echotel 915P electronics for 316/316L (1.4401/1.4404) SST transducer Echotel 915P electronics for Hastelloy C (2.4819) and Monel (2.4360) transducers HOUSING / CABLE / SAFETY APPROVAL – IP65 / WHG § 19 5 6 7 I Y Aluminium, Aluminium, Aluminium, Aluminium, 316 stainless steel, M20 x 1.5 PG 13.5 PG 16 3/4" NPT 3/4" NPT general general general general general purpose purpose purpose purpose purpose and and and and and ATEX ATEX ATEX ATEX ATEX intrinsically intrinsically intrinsically intrinsically intrinsically safe safe safe safe safe HOUSING / CABLE / SAFETY APPROVAL – IP65 / WHG § 19 T M Z K 9 1 5 2 A 0 Aluminium, Aluminium, Aluminium, Aluminium, 0 M20 x 1.5 PG 13.5 PG 16 3/4" NPT ATEX ATEX ATEX ATEX explosion explosion explosion explosion proof proof proof proof complete code for Echotel 915 electronics 5 MODEL IDENTIFICATION 2. Code for Echotel 915 transducer BASIC MODEL NUMBER 9 W 1 9 D 1 Echotel 915-W – Kynar® transducers Echotel 915-P – metal transducers PROCESS CONNECTION Threaded 1 2 9 Threaded 3/4" NPT connection Threaded 1" NPT connection Threaded 1" BSP (G1) connection (minimum length transducer = 50 mm (2") ANSI RF Flanges B C D E F G H J 1" 1 1/2" 2" 1" 1 1/2" 2" 1" 2" 150 150 150 300 300 300 600 600 lbs lbs lbs lbs lbs lbs lbs lbs - Raised Raised Raised Raised Raised Raised Raised Raised Face Face Face Face Face Face Face Face EN EN EN EN EN EN EN EN EN EN EN EN EN EN EN 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 1092-1 Type Type Type Type Type Type Type Type Type Type Type Type Type Type Type DIN Flanges K L M N P Q R S T U V W X Y Z DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN 25/PN 40/PN 50/PN 25/PN 40/PN 50/PN 25/PN 40/PN 50/PN 25/PN 40/PN 50/PN 25/PN 40/PN 50/PN 16, 16, 16, 25, 25, 25, 40, 40, 40, 63, 63, 63, 100, 100, 100, A A A A A A A A A B2 B2 B2 B2 B2 B2 SANITARY Flanges 3 4 5 6 7 8 1 1/2" 2" DN 25, DN 32, DN 40, DN 50, (3 A approved - not for WHG § 19) (3 A approved - not for WHG § 19) DIN 11851 DIN 11851 DIN 11851 DIN 11851 TRANSDUCER MATERIALS K 2 M H K 2 M C M 1 1 1 Kynar (PVDF) 316/316L - 1.4401/1.4404 Monel - 2.4360 Hastelloy C - 2.4819 ACTUATION LENGTH – specify in cm (per 0.39") increments Total insertion length = actuation length + 6 mm (0.25") 0 0 3 3 3 0 9 D 1 6 30 mm - min actuation length 3300 mm - maximum actuation length complete code for Echotel 915 transducers DIMENSIONS IN mm (inches) – ECHOTEL® 915-W Ø 118 (4.63) Ø 118 (4.63) 76 (3) 76 (3) 70 (2.75) 70 (2.75) 97 (3.80 ) 114 ( 4.49) 20 ( 0.79) Actuation length Actuation length 6 (0.25) 6 (0.25) Ø 21 (0.84) Ø 21 (0.84) Flanged unit Threaded unit DIMENSIONS IN mm (inches) – ECHOTEL® 915-P Ø 118 (4.63) Ø 118 (4.63) 76 (3) 76 (3) 70 (2.75) 70 (2.75) 97 (3.80 ) 68 (2.67) 20 (0.79) Actuation Length for 1" BSP (G1) connection Actuation Length for 3/4" NPT connection Actuation 6 (0.25) Ø 22 (0.875) Threaded unit 6 (0.25) Ø 22 (0.875) Flanged unit 7 IMPORTANT SERVICE POLICY Owners of Magnetrol products may request the return of a control; or, any part of a control for complete rebuilding or replacement. They will be rebuilt or replaced promptly. Magnetrol International will repair or replace the control, at no cost to the purchaser, (or owner) other than transportation cost if: a. Returned within the warranty period; and, b. The factory inspection finds the cause of the malfunction to be defective material or workmanship. If the trouble is the result of conditions beyond our control; or, is NOT covered by the warranty, there will be charges for labour and the parts required to rebuild or replace the equipment. In some cases, it may be expedient to ship replacement parts; or, in extreme cases a complete new control, to replace the original equipment before it is returned. If this is desired, notify the factory of both the model and serial numbers of the control to be replaced. In such cases, credit for the materials returned, will be determined on the basis of the applicability of our warranty. No claims for misapplication, labour, direct or consequential damage will be allowed. RETURNED MATERIAL PROCEDURE So that we may efficiently process any materials that are returned, it is essential that a “Return Material Authorisation” (RMA) form will be obtained from the factory. It is mandatory that this form will be attached to each material returned. This form is available through Magnetrol’s local representative or by contacting the factory. Please supply the following information: 1. Purchaser Name 2. Description of Material 3. Serial Number and Ref Number 4. Desired Action 5. Reason for Return 6. Process details All shipments returned to the factory must be by prepaid transportation. Magnetrol will not accept collect shipments. All replacements will be shipped FOB factory. BULLETIN N°: EFFECTIVE: SUPERSEDES: UNDER RESERVE OF MODIFICATIONS www.magnetrol.com ® BE 51-635.5 MAY 2005 October 2003 BENELUX Heikensstraat 6, 9240 Zele, België Tel. +32 (0)52.45.11.11 • Fax. +32 (0)52.45.09.93 • E-Mail: [email protected] DEUTSCHLAND Alte Ziegelei 2-4, D-51491 Overath Tel. 02204 / 9536-0 • Fax. 02204 / 9536-53 • E-Mail: [email protected] FRANCE 40 - 42, rue Gabriel Péri, 95130 Le Plessis Bouchard Tél. 01.34.44.26.10 • Fax. 01.34.44.26.06 • E-Mail: [email protected] ITALIA Via Arese 12, I-20159 Milano Tel. (02) 607.22.98 (R.A.) • Fax. (02) 668.66.52 • E-Mail: [email protected] UNITED KINGDOM Unit 1 Regent Business Centre, Jubilee Road Burgess Hill West Sussex RH 15 9TL Tel. (01444) 871313 • Fax (01444) 871317 • E-Mail: [email protected] INDIA E-22, Anand Niketan, New Delhi - 110 021 Tel. 91 (11) 6186211 • Fax 91 (11) 6186418 • E-Mail: [email protected]